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LOAD BANK MANUAL

Model: PLB-330S9 Serial No S107

Date of mfg. November 2009

For service and information contact: JP Power Technology Inc.

14225-129 Avenue Edmonton, Alberta, T5L 4N9

Tel: 780-456-9167 Fax: 780-478-7135

www.jppowertechnology.ca

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General Information

• JP Power Technology Inc. load banks are air-cooled, definite purpose contactor controlled systems consisting of fused coiled nichrome 60 wire resistors.

• DC load banks are controlled by solid-state components.

• Load bank enclosures are fabricated out of aluminum for a lightweight, corrosion free product. Painting of aluminum enclosures is optional, and steel enclosures are available if a higher strength product is required. Steel enclosures are powder coated.

• Components have been carefully chosen to provide a reliable and easy to use product.

• Load banks are designed to allow easy servicing should repair be necessary.

• Load banks are cooled by an electric fan, which requires a separate power source. As an option, this power source may be contained within the unit.

• Unit electrical ratings are provided in nameplate specifications or drawings.

Warnings

• Load banks emit large quantities of hot air that can reach up to 150˚C (300˚F). Care must be taken to prevent personal injury or property damage.

• Improper operation of load banks while connected to a power source can cause serious damage or personal injury. Follow all applicable rules, laws, and instructions when connecting and operating load banks.

• Ensure that all power sources are turned off before connecting load banks.

• Non-weatherproof units must be placed in a dry and well-ventilated area.

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Setup

• Connect the power source to be tested to the appropriate terminals on the load bank. (See attached diagrams).

• The load bank may or may not be phase sensitive. If a three-phase fan motor

is supplied, airflow direction must be verified.

• Connect a ground cable to the load bank ground connector. A lug marked

“GROUND” is provided on the load bank for one end of the ground cable. The other end should be firmly connected to a suitable ground, such as a plant ground bus, a metal water pipe, or a properly buried rod. The ground cable should be rated for the capacity of the load bank.

• Ensure that cables are placed so that they are safe from being damage and do

not present a hazard.

• Prior to operation, check the load bank’s air intake for foreign objects. Blockage can cause the unit to overheat and result in load test interruption.

• If the fan is interrupted (by a blow fuse or other means), the load contactors will open. No damage to the load bank will occur, but the load test will be interrupted until operation of the fan is regained and the “load on” button is depressed.

Control Circuit The following control equipment is provided with this load bank:

a) Selector switch “ON-OFF” b) Illuminated pushbutton “Press to start test” indicator light (green) c) Illuminated pushbutton “Press to stop test” indicator light (red) d) Load increment switches

Operation A circuit for sensing voltage is included with multi-voltage load banks and will automatically select the correct configuration of contactors.

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• After establishing which load switches will be operated, the equipment can be loaded by following these steps:

1. Establish output from the equipment being loaded according to the manufacturer’s instructions.

2. Select “On-Off” to on. 3. Turn off all of the “step switches”. 4. Press “Start Test” (green) button. 5. Turn on the pre-determined “step switches”. 6. The equipment will now be loaded. 7. Increase or decrease the load by turning the appropriate load step

switches on or off as desired.

• The green light indicates that the load is being applied. Exercise caution around the screen at the air discharge end, as the temperature can become high enough to cause burns.

• It is also possible to “block load” the equipment by turning on the appropriate number of step switches before the “Load On” button is pressed, however this may cause an overload to some systems.

• Never leave the system unattended during load bank operation. Periodic checks should be made of the load bank, the equipment being loaded, as well as all cables and connections.

• After test completion, remove the load by pressing the “Load Off” button. The fan should be left running until the discharge screen and components have cooled.

• The following steps should be taken following completion of the test:

1. Turn off the power source 2. Disconnect the load and ground cables 3. Restore equipment to operational condition. 4. Store the load bank and cables in a dry area.

• If a problem occurs during operation (such as overheating or obstruction of

airflow), the load will automatically disconnect. The fan will continue to operate. The equipment should be checked for any problems and corrected. If the problem persists, the control circuit will not allow the load to be reapplied. When conditions return to normal, the load bank will resume normal operation.

• The following tables and formulas are provided to assist with calculations:

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a) Known

Rated KVA and Power Factor Rating for equipment KW=KVA x Power factor

b) Known

Rated Voltage, Amps & Power Factor Rating for equipment

3Phase

KW=1.732 x Volts x Amps x Power Factor 1000

Note: The amperage listed on the equipment nameplate may not relate to unity power factor loads. To use this figure it must be multiplied by the power factor listed on the equipment nameplate. Example: Most AC alternators are rated at a power factor of 0.8. If the rated amperage is listed as 100 amps on the alternator nameplate, multiply 100 by 0.8 to get 80 amps. 80 amps should be used when calculating the kilowatts.

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KILOWATTS AT UNITY POWER FACTOR (1 PHASE AND DC)

AMPERE 24VDC 48VDC 120VAC 240VAC 480VAC 600VAC10 0.24 0.48 1.20 2.40 4.80 6.00 20 0.48 0.96 2.40 4.80 9.60 12.00 30 0.72 1.44 3.60 7.20 14.40 18.00 40 0.96 1.92 4.80 9.60 19.20 24.00 50 1.20 2.40 6.00 12.00 24.00 30.00 60 1.44 2.88 7.20 14.40 28.80 36.00 70 1.68 3.36 8.40 16.80 33.60 42.00 80 1.92 3.84 9.60 19.20 38.40 48.00 90 2.16 4.32 10.80 21.60 43.20 54.00

100 2.40 4.80 12.00 24.00 48.00 60.00 110 2.64 5.28 13.20 26.40 52.80 66.00 120 2.88 5.76 14.40 28.80 57.60 72.00 130 3.12 6.24 15.60 31.20 62.40 78.00 140 3.36 6.72 16.80 33.60 67.20 84.00 150 3.60 7.20 18.00 36.00 72.00 90.00 160 3.84 7.68 19.20 38.40 76.80 96.00 170 4.08 8.16 20.40 40.80 81.60 102.00 180 4.32 8.64 21.60 43.20 86.40 108.00 190 4.56 9.12 22.80 45.60 91.20 114.00 200 4.80 9.60 24.00 48.00 96.00 120.00 210 5.04 10.08 25.20 50.40 100.80 126.00 220 5.28 10.56 26.40 52.80 105.60 132.00 230 5.52 11.04 27.60 55.20 110.40 138.00 240 5.76 11.52 28.80 57.60 115.20 144.00 250 6.00 12.00 30.00 60.00 120.00 150.00 260 6.24 12.48 31.20 62.40 124.80 156.00 270 6.48 12.96 32.40 64.80 129.60 162.00 280 6.72 13.44 33.60 67.20 134.40 168.00 290 6.96 13.92 34.80 69.60 139.20 174.00 300 7.20 14.40 36.00 72.00 144.00 180.00 310 7.44 14.88 37.20 74.40 148.80 186.00 320 7.68 15.36 38.40 76.80 153.60 192.00 330 7.92 15.84 39.60 79.20 158.40 198.00 340 8.16 16.32 40.80 81.60 163.20 204.00 350 8.40 16.80 42.00 84.00 168.00 210.00 360 8.64 17.28 43.20 86.40 172.80 216.00 370 8.88 17.76 44.40 88.80 177.60 222.00 380 9.12 18.24 45.60 91.20 182.40 228.00 390 9.36 18.72 46.80 93.60 187.20 234.00 400 9.60 19.20 48.00 96.00 192.00 240.00 410 9.84 19.68 49.20 98.40 196.80 246.00 420 10.08 20.16 50.40 100.80 201.60 252.00 430 10.32 20.64 51.60 103.20 206.40 258.00 440 10.56 21.12 52.80 105.60 211.20 264.00 450 10.80 21.60 54.00 108.00 216.00 270.00 460 11.04 22.08 55.20 110.40 220.80 276.00 470 11.28 22.56 56.40 112.80 255.60 282.00 480 11.52 23.04 57.60 115.20 230.40 288.00 490 11.76 23.52 58.80 117.60 235.20 294.00 500 12.00 24.00 60.00 120.00 240.00 300.00

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KILOWATTS AT UNITY POWER FACTOR (3 PHASE)

AMPERE 208VAC 240VAC 440VAC 460VAC 480VAC 600VAC10 3.60 4.16 7.62 7.97 8.31 10.39 20 7.21 8.31 15.24 15.94 16.63 20.79 30 10.81 12.47 22.86 23.90 24.94 31.18 40 14.41 16.63 30.48 31.87 33.26 41.57 50 18.01 20.79 38.11 39.84 41.57 51.96 60 21.62 24.94 45.73 47.81 49.88 62.36 70 25.22 29.10 53.35 55.77 58.20 72.75 80 28.82 33.26 60.97 63.74 66.51 83.14 90 32.42 37.41 68.59 71.71 74.83 93.53

100 36.03 41.57 76.21 79.68 83.14 103.93 110 39.63 45.73 83.83 87.64 91.45 114.32 120 43.23 49.88 91.45 95.61 99.77 124.71 130 46.84 54.04 99.08 103.58 108.08 135.10 140 50.44 58.20 106.70 111.55 116.40 145.50 150 54.04 62.36 114.32 119.51 124.71 155.89 160 57.04 66.51 121.94 127.48 133.03 166.28 170 61.25 70.67 129.56 135.45 141.34 176.67 180 64.85 74.83 137.18 143.42 149.65 187.07 190 68.45 78.98 144.80 151.39 157.97 197.46 200 72.06 83.14 152.42 159.35 166.28 207.85 210 75.66 87.30 160.05 167.32 174.60 218.24 220 79.26 91.45 167.67 175.29 182.91 228.64 230 82.86 95.61 175029 183.26 191.22 239.03 240 86.47 99.77 182.91 191.22 199.54 249.42 250 90.07 103.93 190.53 199.19 207.85 259.82 260 93.67 108.08 198.15 207.16 216.17 270.21 270 97.27 112.24 205.77 215.13 224.48 280.60 280 100.88 116.04 213.39 223.06 232.79 290.99 290 104.48 120.55 221.02 231.06 241.11 301.39 300 108.08 124.71 228.64 239.03 249.42 311.78 310 111.69 128.87 236.26 247.00 257.74 322.17 320 115.29 133.03 243.88 254.00 266.05 332.56 330 118.89 137.18 251.50 262.93 274.36 342.96 340 122.49 141.34 259.12 270.90 282.68 353.35 350 126.10 145.50 266.74 278.87 290.99 363.74 360 129.70 149.65 274.36 286.84 299.31 374.13 370 133.30 153.81 281.99 294.80 307.62 384.53 380 136.91 157.97 289.61 302.77 315.94 394.92 390 140.51 162.12 297.23 310.74 324.25 405.31 400 144.11 166.28 304.85 318.71 332.56 415.70 410 147.71 170.44 312.47 326.67 340.88 426.10 420 151.32 174.60 320.09 334.64 349.19 436.49 430 154.29 178.75 327.71 342.61 357.51 446.88 440 158.52 182.91 335.33 350.58 365.82 457.27 450 162.12 187.07 342.96 358.54 374.13 467.67 460 165.73 191.22 350.58 366.51 382.45 478.06 470 169.33 195.38 358.20 374.48 390.76 488.45 480 172.93 199.54 365.82 382.45 399.08 498.84 490 176.54 203.69 373.44 390.42 407.39 509.24 500 180.14 207.85 381.06 398.38 415.70 219.63